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Study of the effects of important factors on the diameter accuracy of micro-shafts fabricated by TMTF-WEDG

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Abstract

It is very significant to improve the diameter accuracy of micro-shafts fabricated by micro-electrical discharge machining (micro-EDM) in micro-tools application. The diameter accuracy includes the uniformity of a single micro-shaft in axial direction and the repeatability of micro-shafts with the same diameter. A newly proposed method, named twin-mirroring-wire tangential feed electrical discharge grinding (TMTF-WEDG), can realize high uniformity and repeatability of micro-shafts via tangentially feeding and constraining of a narrow slit formed by a twin-mirroring-wire on the diameter of micro-shafts, respectively. Controlling the material removal thickness in single-step machining of micro-shafts is necessary to achieve high uniformity and repeatability. This paper focuses on the effects of the several important factors on the material removal thickness of micro-shafts to reveal the effects on the diameter uniformity and repeatability, including the open voltage, capacitance, feed rate in the Z-direction, feed step in the Y-direction, and tangential feed distance. The results indicate that the lower open voltage or the smaller capacitance or higher Z-direction feed rate, the smaller the thickness of the material removed, which is advantageous for controlling the consistency and repeatability of the micro-shafts. Decreasing of Y-direction feed step from 20 to 5 μm is accompanied by a reduction in material removal thickness, and the material removal thickness of less than 0.4 μm is achieved with a smaller feed step of in the Y-direction. As the tangential feed distance S2 decreases, the material removal thickness of the micro-shafts decreases gradually. In this study, the uniformity and repeatability of brass and tungsten micro-shafts are controlled within 1 μm and 2 μm, respectively.

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Acknowledgments

This research is supported by the National Nature Science Foundation of China (Grant No. 51605323) and the Key Research and Development Program of Shanxi Province (Grant No. 201703D121006).

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Authors and Affiliations

  1. Key Laboratory of Precision Machining of Shanxi Province, College of Mechanical Engineering, Taiyuan University of Technology, 79 West Yingze Street, Wanbailin District, Taiyuan, 030024, Shanxi, China

    Jian-Yu Jia, Yan-Qing Wang, Sheng-Qiang Yang & Wen-Hui Li

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  1. Jian-Yu Jia
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  2. Yan-Qing Wang
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  3. Sheng-Qiang Yang
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  4. Wen-Hui Li
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Correspondence to Yan-Qing Wang or Sheng-Qiang Yang.

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Jia, JY., Wang, YQ., Yang, SQ. et al. Study of the effects of important factors on the diameter accuracy of micro-shafts fabricated by TMTF-WEDG. Int J Adv Manuf Technol 108, 3001–3020 (2020). https://doi.org/10.1007/s00170-020-05412-9

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